Reusable custom insoles

ABSTRACT

A reusable, customizable shoe-insole having an encased viscoelastic material disposed on base of an insole and configured to assume an arch support structure in accordance with sole geometries of each additional user.

BACKGROUND OF THE INVENTION

The present invention relates to shoe insoles, and particularly, relates to custom insoles providing customized arch support adaptable to a plurality of users; each having different arch support needs.

As is known, there are various insole designs providing various levels and types of arch support; some provide universal arch support, while other also provide customized support tailored to each user. Customized insoles typically employ a stiff, single-use material shaped with the aid of heat treatment, computer rendering, foam molding, or a combination of them to match the foot anatomy of each user.

In contrast, some insoles employ a relatively low-viscosity material like a gel or a liquid lacking sufficient stiffness to provide lasting support.

SUMMARY OF THE INVENTION

According to the teachings of the present invention there is provided a custom, reusable shoe insole including a viscoelastic material disposed on a polymeric insole such that weight of each of a plurality of users shapes the viscoelastic material into a customized arch support structure bound in part by a heel bone and at least one metatarsal head of each of the users.

According to a further feature of the present invention, the viscoelastic material is disclosed inside an airtight polymeric encasement.

According to a further feature of the present invention, the viscoelastic material has a mass of about 30 to 40 grams.

According to a further feature of the present invention, the viscoelastic material includes malleable clay.

According to a further feature of the present invention, the putty includes polydimethylsiloxane.

According to a further feature of the present invention, the polymeric encasement is constructed from a polymer selected from the group consisting of polyvinyl chloride, polypropylene, and polyethylene.

According to a further feature of the present invention, the polymeric encasement has an arcuate boundary.

According to a further feature of the present invention, there is also provided a padding layer covering the encasement.

There is also provided according to the teachings of the present invention, providing a polymeric insole; and placing a viscoelastic material on the insole so as to enable the viscoelastic material to assume a first customized arch support structure of a first user stepping on the viscoelastic material and assume a second customized arch support structure of a second user stepping on the first customized arch support structure.

According to a further feature of the present invention, each of the first customized arch support structure and the second customized arch support structure is bound in part by a heel bone and at least one metatarsal head.

According to a further feature of the present invention, the viscoelastic material is disclosed inside an airtight polymeric encasement.

According to a further feature of the present invention, the viscoelastic material has a mass of about 30 to 40 grams.

According to a further feature of the present invention, the viscoelastic material includes malleable putty.

According to a further feature of the present invention, the viscoelastic material includes polydimethylsiloxane.

According to a further feature of the present invention, the polymeric encasement is constructed from a polymer selected from the group consisting of polyvinyl chloride, polypropylene, and polyethylene.

According to a further feature of the present invention, the polymeric encasement has an arcuate boundary.

According to a further feature of the present invention, there is also provided a padding layer covering the encasement.

According to a further feature of the present invention, the padding layer includes slow rebound foam.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The features, their interaction, operation, and advantages may best be understood with reference to the following detailed description in view of the accompanying drawings in which:

FIG. 1 is schematic view of pressure zones of a sole of a first user;

FIG. 2 is schematic top view of reusable custom insole having insole putty disposed in an encasement, according to an embodiment;

FIG. 3 is schematic cross-sectional view of along section line A-A of the insole depicted in FIG. 2, according to an embodiment;

FIG. 4 is schematic top view of reusable custom insole of FIG. 3 with superimposed pressure zones of FIG. 1, according to an embodiment;

FIG. 5 is schematic side view of user stepping onto the insole of FIG. 4, according to an embodiment;

FIG. 6 is schematic side view of the insole of FIG. 5 after user compression of the insole putty of FIG. 5, according to an embodiment;

FIG. 7 is schematic top view of the insole of FIG. 6 after user compression of the insole putty of FIG. 5 depicting the putty borders defined by the high pressure areas, according to an embodiment;

FIG. 8 is schematic view of a sole of a second user depicting weight distribution zones; according to an embodiment;

FIG. 9 is schematic top view of superimposed pressure zones of the second user superimposed on the insole having a putty distribution defined by the pressure zones of the first user, according to an embodiment;

FIG. 10 is schematic side view of a second user stepping onto the customized insole of FIG. 9, according to an embodiment;

FIG. 11 is schematic side view of the insole of FIG. 9 after compression of the insole putty by the second of FIG. 10, according to an embodiment; and

FIG. 12 is schematic top view of the insole after compression of the insole putty by the second user of FIG. 11 in which new putty borders are defined by the high pressure areas of the second user, according to an embodiment.

It will be appreciated that for clarity of illustration, elements shown in the figures have not necessarily been drawn to scale and reference numerals may be repeated in multiple figures to indicate corresponding or analogous elements and well-known methods, procedures, and components are omitted for the sake of clarity.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The present invention relates to custom insole adaptable to multiple users each having his unique anatomical requirements.

The following terminology will be used throughout the document.

“Putty” refers to viscoelastic materials having sufficient viscosity to maintain an arch support structure and sufficient elasticity to be formed into customized multiple arch support structures for multiple users. Malleable clay based and polydimethylsiloxane-based compounds or other non-drying materials providing such functionality are included in the scope of the present invention.

“Heel area”, “heel”, or “heel bone” all refer to the pressure zone created by the calcaneus.

“Inner ball area or medial ball area” refers to the pressure zone created by the first and second metatarsal heads or just the first metatarsal head.

“Outer ball area or lateral ball area” refers to the pressure zone created by the combination of the fourth and fifth metatarsal heads or the fifth metatarsal head.

“Arch” refers to the foot's natural instep area between the heel bone and the first metatarsal head; alternatively, it is referred to as the medial longitudinal arch.

“The lateral longitudinal arch” is the area or zone spanning the heel bone and the fifth metatarsal head.

FIG. 1 is schematic view of various zones of a foot sole of a first user lA depicted in terms of pressure exerted on a support surface when standing. As shown, heel area or heel bone 6A exerts the greatest pressure, followed by inner ball area 3A, outer ball area 4A, lateral longitudinal arch area 5A and medial longitudinal arch or instep 2A. Areas designated 5A located in areas other than longitudinal arch area exert about the same degree of pressure on a support surface like the longitudinal arch area.

FIGS. 2 and 3 are schematic top and transverse, cross-sectional views, respectively, of standard reusable custom insole 10 prior to customization. As shown, insole 10 has insole base 11 molded from ethyl vinyl acetate (E.V.A), according to an embodiment. In a certain embodiment, base 11 is shaped with a heel cup 16 and lacks arch support to facilitate putty spread during shaping

It should be appreciated that insole base 11 constructed from polyurethane, thermo-plastic rubber, nitrol polyvinyl chloride, latex rubber, or a combination of them are included within the scope of the present invention.

As further shown, insole 10 includes putty 12 housed in a polymeric encasement or sealed bag 13 disposed on base insole 11 underneath the arch area (2A of FIG. 1) and follows the contour of inner sloping wall 14 of insole base 11. Polymeric encasement 13 has sufficient volume to receive putty 12 as it spreads into a custom shape upon application of user weight. Encasement volume is also sized so that putty 12 slightly overlaps high pressure zones 6A and 3A prior to a first compression to prevent putty 12 from spreading away from the arch and forming uncomfortable bumps near the edge of encasement 13. Furthermore, encasement 13 prevents putty from spreading into areas in which a second user would be unable to return it to the arch when stepping on insole 10. It should be appreciated that there always exists an option of pushing putty 12 into desired with one' s hand.

Polymeric encasement 13 may be implemented with a variety of flexible yet strong polymeric materials like polyvinyl chloride, polypropylene, polyethylene, or various other materials providing such functionality. Furthermore, putty encasements achieved through insole base and top padding materials are also included within the scope of the present invention.

Putty 12 is sufficiently elastic to spread responsively to the application of relatively high pressure from heel area 6A and medial ball area 3A; but, sufficiently viscous to hold the new shape and provide support to arch 2A (Shown in FIG. 1).

In a certain embodiment putty composition includes either a volume or a weight composition of chloroprene 7%, mineral oil 13%, cold factice 8%, and calcium powder 71.5% and in another embodiment Plasticine® is employed.

In a certain examples, putty 12 has a quantity ranging between about 30-40 grams for a man's US size 10 shoe to enable an arch support structure having a height of 14 mm and spanning an insole area of about 7.0×4.5 cm.

Sample viscosities range from approximately 100,000,000 centipoise for a man's US size 10 shoe to 50,000,000 centipoise for children. It should be appreciated that other viscosities providing such functionality are included within the scope of the invention.

FIG. 3 is schematic cross-sectional view of along section line A-A of insole 10 depicted in FIG. 2, according to an embodiment. As depicted, encased putty 12 is covered with a padding layer 16 constructed from slow rebound foam having a rebound time of over a minute to fully rebound from compression, according to an embodiment. Typical examples of rebound foam are, inter alia, viscoelastic polyurethane foam or EVA modified. It should be appreciated that in certain embodiments, a combination of quick slow rebound foam are employed in padding layer 16.

Padding layer 16 implemented with rebound foam advantageously provides additional customization to the toes and other low pressure zones without crowding the foot.

Furthermore, slow rebound foam advantageously provides additional foot ventilation and use of a thicker, more comfortable padding layer 16. A flexible top fabric (not shown) covering padding layer 16 also conforms to foot geometry. Typical examples of top fabric include cotton, polyester, and polypropylene

FIG. 4 is schematic top view of reusable custom insole 10A depicting the pressure zones associated with a first user relative to insole elements.

As shown, heel area 6A, inner ball area 3A, putty 12 overlap such that when downward pressure is applied to putty 12 by a user a portion of the putty 12 shifts from these high pressure areas to the lower pressure areas; outer ball area 4A, lateral longitudinal arch area 5A. Remaining putty 12 forms an arch support structure in accordance with sole geometry defined in part by heel area 6A, medial ball area 3A and inner sole wall 14.

FIGS. 5 and 6 are schematic side views of putty compression prior to and after the application of user weight achieved by stepping onto insole 10A. As shown, putty 12 is disposed in its pre-compression position on base 12 underneath padding layer 16 in alignment with medial longitudinal arch 18A associated with first user 20A. In FIG. 6 putty 12A is shifted into a new positon conforming to the geometry of arch 18A of first user 20A. Putty 12A is bound in part by the high pressure applied by heel area as depicted by vector arrows 21A and 22A and high pressure applied by the inner ball area as depicted by vector arrows 23A and 24A, according to an embodiment.

The encased putty together with the absence of hard plastic advantageously provides customized arch support without sacrificing comfort.

FIG. 7 is schematic top view of the customized putty shape after user compression. As shown, putty borders are defined by heel area 6A and inner ball area 3A whereas putty 12A has spread beyond the inner lower pressure boundaries of outer ball area 4A lateral longitudinal arch area 5A.

FIG. 8 is schematic view of a sole 1B of a second user depicting analogues weight distribution zones; heel area 6B, inner ball area 3B, outer ball area 4B, lateral longitudinal arch area 5B and medial longitudinal arch or instep 2B. As shown, the weigh distribution zones of sole 1B of a second user have different geometries than the corresponding zones of the first user.

FIG. 9 is schematic top view of pressure zones of second user superimposed on a previously customized insole having a putty distribution defined by the pressure zones of first user. As shown, putty 12A is no longer bound by heel area 6B and medial ball area 3B.

FIGS. 10 and 11 are schematic side views of re-customization of insole 10A to match the sole anatomy of second user.

As shown in FIG. 10, putty 12A is accumulated in accordance with the arch geometry of a first user as shown in FIG. 6. Foot 20B of second user has a less arcuate arch 18B thereby rendering first insole 10A unusable for him in the absence of modification.

As shown in FIG. 11 putty 12B is shifted into a new positon conforming to the geometry of arch 18B of foot 20A of second user. Putty 12B is bound in part by the high pressure applied by heel area as depicted by vector arrows 21B and high pressure applied by the inner ball area as depicted by vector arrows 26B as the flatter arch of second user's foot 20B applies a downward force 25B to form a re-customized arch support structure from putty 12B.

This multi-user adaptability has many applications. For example, an unsatisfied customer is able return customized insoles to a store without the store suffering a loss because the store has the ability to re-customizes the insoles to the next buyer.

It should be appreciated that customization from a user having a low arch to one having a high arch requires pushing the putty by into the midsole area opposite the arch so that a new user can then step on the putty to distribute it in accordance with his sole geometry as previously described.

FIG. 12 is schematic top view of the customized putty shape after compression of a second user. As shown, putty borders are defined by variant heel area 6B and inner ball area 3B of the second user whereas putty 12B has spread beyond the inner lower pressure boundaries of outer ball area 4B lateral longitudinal arch area 5B.

It should be appreciated that various combinations of features and methods not explicitly set forth in one particular embodiment are also within the scope of the present invention. 

What is claimed is:
 1. A custom, reusable shoe insole comprising: a viscoelastic material disposed on a polymeric insole such that weight of each of a plurality of users shapes the viscoelastic material into a customized arch support structure bound in part by a heel bone and at least one metatarsal head of each of the users.
 2. The custom reusable shoe insole of claim 1, wherein the viscoelastic material is disclosed inside an airtight polymeric encasement.
 3. The custom reusable shoe insole of claim 2, wherein the viscoelastic material has a mass of about 30 to 40 grams.
 4. The custom reusable shoe insole of claim 2, wherein the viscoelastic material includes malleable clay.
 5. The custom reusable shoe insole of claim 4, wherein the viscoelastic material includes polydimethylsiloxane.
 6. The custom reusable shoe insole of claim 2, wherein the polymeric encasement is constructed from a polymer selected from the group consisting of polyvinyl chloride, polypropylene, and polyethylene.
 7. The custom reusable shoe insole of claim 2, wherein the polymeric encasement has an arcuate boundary.
 8. The custom reusable shoe insole of claim 2, further comprising a padding layer covering the encasement.
 9. A method of constructing a custom, reusable shoe insole, the method comprising: providing a polymeric insole base; and placing a viscoelastic material on the insole base so as to enable the viscoelastic material to assume a first customized arch support structure of a first user stepping on the viscoelastic material and assume a second customized arch support structure of a second user stepping on the first customized arch support structure.
 10. The method of claim 9, wherein each of the first customized arch support structure and the second customized arch support structure is bound in part by a heel bone and at least one metatarsal head.
 11. The method of claim 9, wherein the viscoelastic material is disclosed inside an airtight polymeric encasement.
 12. The method of claim 11, wherein the viscoelastic material has a mass of about 30 to 40 grams.
 13. The method of claim 11, wherein the viscoelastic material includes malleable putty.
 14. The custom reusable shoe insole of claim 13, wherein the viscoelastic material includes polydimethylsiloxane.
 15. The custom reusable shoe insole of claim 11, wherein the polymeric encasement is constructed from a polymer selected from the group consisting of polyvinyl chloride, polypropylene, and polyethylene.
 16. The custom reusable shoe insole of claim 11, wherein the polymeric encasement has an arcuate boundary.
 17. The custom reusable shoe insole of claim 11, further comprising a padding layer covering the encasement.
 18. The custom reusable shoe insole of claim 17, wherein the padding layer includes slow rebound foam. 